Cantilevered and textured concrete form

ABSTRACT

This invention relates to an apparatus for forming a textured cantilevered concrete edge. The apparatus includes an inner wall form adjacent to a taller outer wall form resulting in a textured edge for receiving the concrete. A L-shape liner with a horizontal foot and a vertical riser is supported by the inner wall form and braced by the outer wall form. The liner includes a textured surface on the concrete-contacting face. Combinations of straight segments and curved segments frame a perimeter for the concrete pour. This invention also relates to the method of use of the apparatus for forming a textured cantilevered concrete edge.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 60/843,080 filed on 8 Sep. 2006.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to an apparatus and method for forming and texturing concrete.

2. Description of Related Art

Known concrete forms cast steps, such as for use with buildings but lack aesthetic texturing. Other concrete casting techniques include stamping brick shapes into poured horizontal concrete for driveways.

There is a need for a concrete edge forming apparatus that results in a fixed and rigid adherence and consistent relationship between casting members to form a textured edge.

SUMMARY OF THE INVENTION

Accordingly, it is one object of this invention to provide an apparatus for forming a textured concrete edge. It is another object of this invention to provide an apparatus for texturing the edge of the concrete.

These and other objects of this invention are met at least in part by an apparatus for forming a concrete edge including an inner wall form and an outer wall form at least partially adjacent to the inner wall form. The inner wall form and the outer wall form combine together as a support member and frame a cantilevered shape for receiving the concrete in straight and/or curved segments.

The apparatus includes a liner supported by at least one of the inner wall form and the outer wall form with a generally horizontal foot in combination with a generally vertical riser. The liner has a pattern in at least a portion of a concrete-contacting face for texturing the concrete. One or more fasteners secure the liner to the inner wall form, and one or more stakes anchor the apparatus during concrete forming.

The inner wall form and outer wall form may be constructed of wood, dimensional lumber, aluminum, steel and/or foam. The liner may be constructed of polyurethane, polystyrene and/or neoprene rubber. A width of the liner may be about 1 cm to about 15 cm and a height of the liner may be about 1 cm to about 20 cm. The thickness of the riser may be about 0.5 cm to about 2.0 cm and the thickness of the foot may be about 0.25 cm to about 1.5 cm. The texture pattern may include hewn rock, brick, tile, stone and/or wood.

The invention also includes a method of forming a concrete edge including aligning an inner wall form with an outer wall form so that a textured surface results for forming the concrete, framing at least one perimeter which may include a curve for receiving at least a portion of the concrete with an inner wall form in combination with an outer wall form, adding reinforcement within the framed perimeter, and providing a liner having a generally horizontal foot and a generally vertical riser.

The method further includes supporting the foot of the liner on the inner wall form, supporting the riser of the liner against the outer wall form, mixing cement, aggregate, and water to form the concrete and adding a colorant to the concrete, pouring the concrete into a resulting form, leveling the concrete with a top of the outer wall form, allowing the concrete to cure or dry and removing the outer wall form, the inner wall form and the liner from the concrete.

The method may produce stairs, curbs, patios, retaining walls, hot tubs, tiered structures and/or swimming pools.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects and features of this invention will be better understood from the following descriptions taken in conjunction with the drawings wherein:

FIG. 1 is an isometric view of a concrete forming apparatus, according to one preferred embodiment of this invention;

FIG. 2 is a partial side sectional view of a concrete forming apparatus, according to one preferred embodiment of this invention;

FIG. 3 is a side view of a liner, according to one preferred embodiment of this invention;

FIG. 4 is a partial side sectional view of a tiered structure, according to one preferred embodiment of this invention; and

FIG. 5 is a partial top view of a perimeter, according to one preferred embodiment of this invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Many building materials, such as, for example, concrete are cast, molded, formed, sculpted, stamped and/or shaped into various shapes, forms and textures. Typically, concrete may include cement, sand, aggregate, fibers, stone and/or any other suitable filler or binder material. Masonry, broadly includes without limitation, laying or stacking of substantial material, such as stone or brick. Other similar materials may include, without limitation, plaster, stucco, mortar, grout, tile and any other relatively durable suitable material or substance. Engineered materials, such as high strength concrete or epoxy-based grouts may be also considered masonry materials. Wood, metal and any other suitable ornamental or structural material may be included as inlays, surface applications or embedded within the finished product. Stone broadly includes natural, synthetic and cultured varieties, such as may be used in a raw and/or cut form, for example. Masonry materials may be further modified, for example, by the use of pigments, colorants, stains, paints, sealers and/or any other material to affect a desired characteristic. Other possible materials may include foams, fiberglass and/or reinforced plastics, such as made from recycled materials and may be used in playground equipment.

Masonry materials may include residential and/or commercial applications, such as stairs, retaining walls, curbs, edges, lips, coping, patios, sidewalks, parking decks, hot tubs, swimming pools, saunas, tiered structures, landscaping structures, counter tops and/or any other suitable applications or uses. Uses broadly include design, decorative or aesthetic applications, as well as structural or functional applications. Often, but not necessarily, additional supporting or strengthening materials are added to concrete structures, such as rebar, plate, bar, wire, screen, mesh, foam and/or any other suitable substance improving the performance of the structure.

As shown in FIG. 1 and according to a preferred embodiment of this invention, apparatus 10 forms or makes textured edge 14, such as a cantilevered edge, to mold and texture concrete 12. Apparatus 10 may also be referred to as an edge form, a masonry form and/or master form 50. The term “cantilevered” refers broadly to an overhanging, extending and/or generally externally unsupported structure, for example, as found on the leading edge of some steps.

Desirably, apparatus 10 includes inner wall form 70 at least partially adjacent to taller or higher outer wall form 60, such as, for example, to make cantilevered shape 14. Inner wall form 70 or lower retainer may include wood, dimensional lumber, aluminum, steel, flexible steel, plywood, particle board, man-made wood products, plastic, foam and/or any other suitable at least semirigid concrete forming or shaping material.

According to a preferred embodiment of this invention and as shown in FIG. 5, inner wall form 70 may form straight lengths 78 and/or curved lengths 76. Desirably, a material of inner wall form 70 allows or accommodates a desired radius or combinations of bends, such as with flexible foam. Any desired combination of linear and/or arcuate forms are possible.

Inner wall form 70 can be any desired size and/or shape, such as for example a thickness of about 1 cm to about 20 cm, preferably about 2 cm to about 5 cm and most preferably about 3.8 cm. Inner wall form 70 may have a height of about 1 cm to about 40 cm, preferably about 5 cm to about 20 cm and most preferably about 9 cm. A length of inner wall form 70 depends upon the boundary and desired edge, such as to form perimeter 54. Advantageously, inner wall form 70 preferably utilizes nominal readily-available sizes of conventional dimensional lumber, such as 2×4s, 2×6s and/or any other desirable sizes.

During and after a pour, inner wall form 70 may retain at least a portion of concrete 12 and desirably has a surface interface for a suitable finish on the contacting portion of concrete 12.

Outer wall form 60 or upper retainer aligns generally parallel with inner wall form 70, such as to form supporting member 52, as shown in FIG. 2 and according to a preferred embodiment of this invention. Those skilled in the art and guided by the teachings herein, readily appreciate supporting member 52 may include a unitized or single piece design versus a separate inner wall form 70 and outer wall form 60.

Outer wall form 60 may have any of the characteristics and properties discussed above with regard to inner wall form 70. According to a preferred embodiment of this invention, outer wall form 60 is at least 2 cm taller, preferably at least 5 cm taller and most preferably about 6.3 cm taller than inner wall form 70. Outer wall form 60 and inner wall form 70 may be joined or fastened by any suitable mechanism, such as nails, screws, bolts, adhesives and/or any other suitable mechanical or chemical anchoring devices.

According to a preferred embodiment of this invention and as shown in FIGS. 2 and 3, apparatus 10 includes liner 20. Liner 20 may be at least partially disposed within textured edge 14 and supported by at least one of inner wall form 70 and outer wall form 60.

Liner 20 may be any size and/or shape. Desirably, liner 20 has L-shape 46 made of a generally horizontal element or foot 40 and a generally vertical element or riser 42.

Liner 20 may comprise polyurethane, polyvinyl chloride, neoprene rubber, polystyrene foam, wax, clay, plaster and/or any other suitable forming material for shaping concrete 12. Desirably, liner 20 is flexible, resilient and semirigid, such as withstands the pressures of pouring and curing concrete 12 in desired shapes. Liner 20 may be disposable, such as a one time use or may be reusable, such as for multiple uses. Liners 20 for multiple uses desirably are washable and/or cleanable to prepare face 32 for the next application. Face 32 or forming surface includes a portion that contacts or touches an interface of concrete 12.

Foot 40 may include any suitable size and/or shape, such as a width of about 1 cm to about 15 cm. According to a preferred embodiment of this invention, foot 40 has a width generally equal to and supported by a width of inner wall form 70. Foot 40 may include a thickness of about 0.25 cm to about 1.5 cm, preferably about 0.6 cm.

Riser 42 may include any suitable size and/or shape, such as a height of about 1 cm to about 20 cm. According to a preferred embodiment of this invention, riser 42 has a height generally equal to and supported by a height of outer wall form 60 extending above inner wall form 70. Riser 42 may include a thickness of about 0.5 cm to about 2.0 cm, preferably about 1.3 cm.

Liner 20 may further include textured surface 30 or pattern. Desirably, textured surface 30 adds, shapes, and/or molds a three-dimensional shape or finish to concrete 12 and forms textured concrete 34, as shown in FIG. 4. Textured surface 30 may include virtually any suitable repeating or nonrepeating pattern.

According to a preferred embodiment of this invention, textured surface 30 is a reverse or a mirror image of the desired finished product, such as, for example, hewn or rough cut stone, brick, tile, wood, orange peel, stone, finished stone and any other suitable aesthetic design.

Desirably, textured surface 30 may also provide functional features to concrete 12, such as nonslip traction and/or water draining features. The pattern may be disposed on riser 42 opposite outer wall form 60.

Textured surface 30 generally, but not necessarily, is on vertical riser 42 and may extend onto a portion of foot 40. Foot 40 typically contacts the underside of the textured edge 14 which may not be readily visible so additional texturing is not needed. Similarly, foot 40 provides a suitable location for fastener 44 since any imperfections fastener 44 forms in concrete 12 on the bottom of textured edge 14 are generally not visible.

Fastener 44 may include broadly nails, trim nails, common nails, brads, tacks, spikes, screws, bolts, fasteners, hook and loop fasteners, glues, adhesives and/or any other suitable permanent or temporary securing mechanisms. Fastener 44 may affix or mount liner 20 to supporting member 52 in any suitable location. According to a preferred embodiment of this invention, fastener 44 is a trim nail with a small head to minimize any distortion of liner 20 while attaching to supporting member 52.

Alternately, liner 20 may include a portion extending on or along at least a portion of the height of inner wall form 70. Desirably, the extension includes textured surface 30 to pattern concrete 12, such as a back of a step.

According to another embodiment of this invention, liner 20 includes molded or shaped corners or corner pieces, such as about 90 degrees or any other suitable angle. Corner pieces may include both inside and outside configurations or shapes. Desirably, corner pieces are secured with fastener 44 to supporting member 52. Alternately, liner 20 may be cut or mitered into a desired angle, such as during field use.

Liner 20 may be supplied in precut lengths and sheets or may be supplied on a roll and cut to a desired length. According to a preferred embodiment of this invention, liner 20 forms or shapes a rounded, chamfered or eased edge, such as a bullnose, a double bullnose or any other suitable at least partially radiused shape. Alternately, liner 20 forms or shapes a crisp or sharp edge.

Apparatus 10 may include stake 48, such as for securing or anchoring at least a portion of apparatus 10, such as to the ground. Stake 48 may include wood, metal and any other suitable material of any suitable size or shape. Typically, but not necessarily, stake 48 is attached to outer wall form 60, for example with a nail.

As shown in FIG. 4 and according to a preferred embodiment of this invention, apparatus 10 may form stairs 72 as a tiered structure 74, for example, by adding a second perimeter 54. There is no limit as to the number of tiers possible, such as for a flight of steps. Desirably, concrete 12 may include reenforcement 80, such as any of the strengthening materials described above.

Stairs 72 generally include a plurality of stair treads 80 and stair risers 84. Stair tread 80 or generally horizontal stepping surface may be any suitable dimension, such as a width of about 20 cm to about 30 cm, preferably about 23 cm to about 28 cm. Stair riser 84 or generally vertical gain may be any suitable dimension, such a height of about 15 cm to about 25 cm, preferably about 18 to about 20 cm. The rise and run of stairs 72 can be any suitable dimension as if supported by an appropriate stringer with allowance for desired overhang 86.

One skilled in the art and guided by the teachings herein will appreciate that any desired holes, apertures, pipes, conduits, raceways and/or any other suitable feature may be included in concrete 12, such as for electrical power supply to low voltage lighting on a patio or a water supply to a fountain in a koi pond.

This invention also includes a method of forming a concrete edge. The method may include the following steps without limitation of order, combination, omission and/or repetition.

The method may include the step of aligning inner wall form 70 with outer wall form 60 so that textured edge 14 results for forming concrete 12 and the step of framing perimeter 54 for receiving at least a portion of concrete 12 with inner wall form 70 in combination with outer wall form 60. Optionally, the method may include the step of framing may include at least one curve and/or framing one or more additional perimeters 54, such as for tiered structure 74. The method may include the step of anchoring at least one of inner wall form 70 and outer wall form 60 with stake 48 and the step of providing liner 20 having foot 40 and riser 42.

The method may include the step of attaching liner 20 with fastener 44 to inner wall form 70. The method also may include the step of adding reinforcement 80 within framed perimeter 54 and the step of mixing cement, aggregate, and water to form concrete 12 and optionally adding a colorant to concrete 12. The method may further include the step of pouring concrete 12 into textured edge 14 and the step of removing one or more stakes 48 while pouring concrete 12 into a tiered structure 74, such as once the first layer is filled and some material has been added to the second layer to hold apparatus 10 in place and on top of the first layer. The holes from the stakes 48 may be filled with additional concrete 12. The method also may include the step of leveling concrete 12 with a top of outer wall form 60 and the step of allowing concrete 12 to cure, dry and/or become solid. Another step in the method may include removing outer wall form 60, inner wall form 70 and liner 20 from concrete 12.

The steps of the method can be used for forming stairs, curbs, patios, retaining walls, hot tubs, swimming pools and any other suitable applications.

While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention. 

1. An apparatus for forming concrete, the apparatus comprising: an inner wall form retaining at least a portion of the concrete; an outer wall form at least partially adjacent to the inner wall form, the inner wall form and the outer wall form together frame a cantilevered shape for receiving the concrete; a liner at least partially disposed within the cantilevered shape and supported by at least one of the inner wall form and the outer wall form, the liner comprising a generally horizontal foot in combination with a generally vertical riser, the liner having a pattern in at least a portion of a concrete face for texturing the concrete.
 2. The apparatus for forming concrete of claim 1, further comprising at least one fastener securing the liner to the inner wall form.
 3. The apparatus for forming concrete of claim 1, wherein the inner wall form and the outer wall form comprise at least one of the group consisting of wood, dimensional lumber, aluminum, steel and foam.
 4. The apparatus for forming concrete of claim 1, wherein the liner comprises at least one of the group consisting of polyurethane, polystyrene and neoprene rubber.
 5. The apparatus for forming concrete of claim 1, wherein the liner has a generally L-shape cross section with the pattern disposed on the riser opposite the outer wall form.
 6. The apparatus for forming concrete of claim 1, wherein a width of the liner is about 1 cm to about 15 cm.
 7. The apparatus for forming concrete of claim 1, wherein a height of the liner is about 1 cm to about 20 cm.
 8. The apparatus for forming concrete of claim 1, wherein the texture of the pattern is selected from the group consisting of hewn rock, brick, tile, stone, wood and combinations thereof.
 9. The apparatus for forming concrete of claim 1, wherein the apparatus forms an edge selected from the group consisting of straight, curved and combinations thereof.
 10. The apparatus for forming concrete of claim 1, further comprising at least one stake anchoring at least a portion of the apparatus during concrete forming.
 11. A cantilevered masonry form comprising: a generally L-shape liner textured on at least a portion of a forming surface; a support member backing the L-shape liner; and a fastener attaching the L-shape liner to the support member.
 12. The masonry form of claim 11, wherein: the liner has a generally vertical element and a generally horizontal element; the generally vertical element has a thickness of about 0.5 cm to about 2.0 cm; and the generally horizontal element has a thickness of about 0.25 cm to about 1.5 cm.
 13. A method of forming a concrete edge comprising: aligning an inner wall form with an outer wall form so that a cantilevered shape results for forming the concrete; framing a perimeter for receiving at least a portion of the concrete with an inner wall form in combination with an outer wall form; providing a liner having a generally horizontal foot and a generally vertical riser; supporting the foot of the liner on the inner wall form; supporting the riser of the liner against the outer wall form; pouring concrete into the cantilevered shape; allowing the concrete to cure; and removing the outer wall form, the inner wall form and the liner from the concrete.
 14. The method of forming a concrete edge of claim 13, further comprising: mixing cement, aggregate, and water to form the concrete; and adding a colorant to the concrete.
 15. The method of forming a concrete edge of claim 13, wherein the concrete edge forms at least one of group consisting of stairs, curbs, patios, retaining walls, hot tubs and swimming pools.
 16. The method of forming a concrete edge of claim 13, wherein the framing a perimeter includes at least one curve.
 17. The method of forming a concrete edge of claim 13, further comprising: anchoring at least one of the inner wall form and the outer wall form with a stake.
 18. The method of forming a concrete edge of claim 13, further comprising: framing a second perimeter and forming a tiered structure.
 19. The method of forming a concrete edge of claim 13, further comprising: leveling the concrete with a top of the outer wall form.
 20. The method of forming a concrete edge of claim 13, further comprising: adding reinforcement within the framed perimeter. 